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United States Patent |
6,186,106
|
Glovatsky
,   et al.
|
February 13, 2001
|
Apparatus for routing electrical signals in an engine
Abstract
There is disclosed herein an apparatus for routing electrical signals in an
engine having n cylinders and an intake manifold, one embodiment of which
comprises: (1) a generally rigid housing generally conforming in shape
with and being removably attachable to a top surface of the intake
manifold; (2) at least n carrier members attached to the housing and
extending outward therefrom, wherein each carrier member is arranged in
general proximity with a respective cylinder; (3) a plurality of
conductive circuit traces arranged on or within an underside or other
surface of the housing and on or within each carrier member; and (4) at
least one input/output connector for connection to at least one of an
external signal source, an external power source, an external signal
destination, and an external power destination, wherein each input/output
connector is attached to the housing and is electrically connected to at
least one of the circuit traces. Each circuit trace carried by each
carrier member terminates in a termination electrically connectable with
an electrical engine element, such as an ignition coil, an electronic fuel
injector, a spark plug, and/or a glow plug.
Inventors:
|
Glovatsky; Andrew Z. (Livonia, MI);
Lemecha; Myron (Dearborn, MI);
Miller; Mark (Monroe, MI);
Baker; Jay DeAvis (West Bloomfield, MI)
|
Assignee:
|
Visteon Global Technologies, Inc. (Dearborn, MI)
|
Appl. No.:
|
999077 |
Filed:
|
December 29, 1997 |
Current U.S. Class: |
123/143C; 123/184.61 |
Intern'l Class: |
F02P 023/00; F02M 035/10 |
Field of Search: |
123/184.61,143 C,456,169 PH
174/52.2,19,24,315,17 R
|
References Cited
U.S. Patent Documents
2234579 | Mar., 1941 | Robertson | 123/148.
|
4050093 | Sep., 1977 | Crall et al. | 361/383.
|
5003933 | Apr., 1991 | Rush, II et al. | 123/52.
|
5086743 | Feb., 1992 | Hickey | 29/602.
|
5178115 | Jan., 1993 | Daly | 123/470.
|
5189782 | Mar., 1993 | Hickey | 123/468.
|
5203292 | Apr., 1993 | Motose | 123/143.
|
5261375 | Nov., 1993 | Rush, II et al. | 123/470.
|
5347969 | Sep., 1994 | Gmelin et al. | 123/456.
|
5353758 | Oct., 1994 | Masuda et al. | 123/143.
|
5357931 | Oct., 1994 | Semence | 123/456.
|
5477819 | Dec., 1995 | Kopec | 123/184.
|
Primary Examiner: Kamen; Noah P.
Assistant Examiner: Gimie; Mahmoud M
Attorney, Agent or Firm: Hodges; Leslie C.
Claims
What is claimed is:
1. A flex circuit for routing electrical signals in an internal combustion
engine having n cylinders and an intake manifold, comprising:
a flex circuit substrate having a body portion and at least n arm portions
extending outward from said body portion, wherein said body portion
generally conforms in shape with a top surface of the intake manifold, and
wherein each arm portion is arranged in general proximity with a
respective cylinder;
a plurality of conductive circuit traces arranged on or within at least one
surface of said body portion and of each arm portion; and
at least one input/output connector for connection to at least one of an
external signal source, an external power source, an external signal
destination, and an external power destination, wherein each input/output
connector is attached to said substrate and is electrically connected to
at least one of said circuit traces;
wherein each circuit trace carried by each arm portion terminates in a
termination electrically connectable with an electrical engine element.
2. A flex circuit according to claim 1, wherein said electrical engine
element is one of an ignition coil, an electronic fuel injector, a spark
plug, and a glow plug.
3. A flex circuit according to claim 1, further comprising a cover capable
of covering substantially all of said body portion and at least part of
each of said arm portions, said cover being removably attachable to the
intake manifold.
4. A flex circuit according to claim 1, further comprising a plurality of
electronic components operably attached to said circuit traces.
5. A flex circuit according to claim 4, wherein said electronic components
comprise components from at least one electronic control module selected
from the group consisting of an engine control module, a mass air flow
sensor module, an anti-lock brake control module, a speed control module,
a throttle control module, and a fuse box module.
6. A flex circuit according to claim 1, wherein each termination of each
circuit trace on each arm portion is one of a male plug connector, a
female socket connector, and a generally flat contact pad.
7. A flex circuit according to claim 1, wherein a rigid substrate member is
attached to an end of each arm portion, wherein each termination of each
circuit trace on or within each arm portion is disposed on said rigid
substrate member.
8. A flex circuit according to claim 1, wherein said substrate is removably
attachable to the top surface of the intake manifold.
9. A flex circuit according to claim 1, wherein said substrate has a hole
in said body portion through which a top portion of the intake manifold or
an end portion of an air intake duct may extend.
10. A flex circuit according to claim 1, wherein said body portion of said
substrate includes at least one rigid substrate portion thereof.
11. A flex circuit according to claim 1, wherein said substrate has n arm
portions wherein circuit traces on or within each arm portion have
terminations electrically connectable with an ignition coil and an
electronic fuel injector associated with the respective cylinder thereof.
12. A flex circuit according to claim 11, wherein each arm portion
generally conforms in shape with a top runner surface associated with the
respective cylinder thereof.
13. A flex circuit according to claim 1, wherein said substrate has n arm
portions each of which divides into first and second branches, wherein
circuit traces on or within each first branch have terminations
electrically connectable with an ignition coil and wherein circuit traces
on or within each second branch have terminations electrically connectable
with an electronic fuel injector.
14. A flex circuit according to claim 1, wherein said substrate has 2n arm
portions wherein circuit traces on or within each arm portion have
terminations electrically connectable with one of an ignition coil and an
electronic fuel injector.
15. An intake manifold cover for routing electrical signals in an internal
combustion engine having n cylinders and an intake manifold, comprising:
a generally rigid housing generally conforming in shape with and being
removably attachable to a top surface of the intake manifold;
at least n carrier members attached to said housing and extending outward
therefrom, wherein each carrier member is arranged in general proximity
with a respective cylinder;
a plurality of conductive circuit traces arranged on or within a surface of
said housing and on or within each carrier member; and
at least one input/output connector for connection to at least one of an
external signal source, an external power source, an external signal
destination, and an external power destination, wherein each input/output
connector is attached to said housing and is electrically connected to at
least one of said circuit traces;
wherein each circuit trace carried by each carrier member terminates in a
termination electrically connectable with an electrical engine element.
16. An intake manifold cover according to claim 15, wherein said electrical
engine element is one of an ignition coil, an electronic fuel injector, a
spark plug, and a glow plug.
17. An intake manifold cover according to claim 15, wherein at least some
of said circuit traces are arranged on or within a flexible substrate
attached to the surface of said housing.
18. An intake manifold cover according to claim 15, wherein at least some
of said circuit traces are arranged on a rigid substrate attached to the
surface of said housing.
19. An intake manifold cover according to claim 15, further comprising a
plurality of electronic components operably attached to said circuit
traces.
20. An intake manifold cover according to claim 19, wherein said electronic
components comprise components from at least one electronic control module
selected from the group consisting of an engine module, a mass air flow
sensor module, an anti-lock brake control module, and a fuse box module.
21. An intake manifold cover according to claim 15, wherein each
termination of each circuit trace on or within each carrier member is one
of a male plug connector, a female socket connector, and a generally flat
contact pad.
22. An intake manifold cover according to claim 15, wherein a rigid
substrate member is attached to an end of each carrier member, wherein
each termination of each circuit trace on or within each carrier member is
disposed on said rigid substrate member.
23. An intake manifold cover according to claim 15, wherein said housing
has a hole therein through which a top portion of the intake manifold or
an end portion of an air intake duct may extend.
24. An intake manifold cover according to claim 15, wherein said housing
comprises a body portion and at least n arm portions extending outward
from said body portion, wherein said body portion generally conforms in
shape with the top surface of the intake manifold, and wherein each arm
portion is arranged in general proximity with a respective cylinder.
25. An intake manifold cover according to claim 24, wherein at least part
of each carrier member is attached to a respective arm portion.
26. An intake manifold cover according to claim 15, wherein each carrier
member comprises an outwardly extending integral arm portion of said
generally rigid housing.
27. An intake manifold cover according to claim 15, wherein each carrier
member is generally elongate in shape.
28. An intake manifold cover according to claim 15, wherein each carrier
member generally conforms in shape with a top runner surface associated
with the respective cylinder thereof.
29. An intake manifold cover according to claim 15, wherein each carrier
member is an electrically insulative flexible substrate.
30. An intake manifold cover according to claim 29, wherein said
electrically insulative flexible substrate is made of a flexible
elastomer.
31. An intake manifold cover according to claim 15, wherein said generally
rigid housing is made of a polymeric material.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to engines having air induction
systems, such as internal combustion engines. More particularly, the
present invention relates to an apparatus for routing electrical signals
in an engine having an air intake manifold.
2. Disclosure Information
Most engines, such as internal combustion engines, have an air intake
manifold 50 for taking in air from outside the engine 30 and directing it
into each engine cylinder, as illustrated in FIGS. 1-2. The outside air
flows in through an air intake duct 56 into a central air chamber, from
which it is then directed into individual runners or channels 54 and into
each individual engine cylinder where combustion takes place.
Combustion is typically facilitated by activating a spark from a spark plug
within the cylinder of a gasoline engine, or by activation of a glow plug
within the cylinder of a diesel engine. Such activation is generally
accomplished by supplying either pulsed or continuous electrical signals
or power feeds to the spark plug or glow plug. These signals or power
feeds in turn typically come from either a central distributor, or from
individual ignition coils at each cylinder. In fuel injected engines, it
may also be desirable to have an individual electronic fuel injector (EFI)
disposed proximate each cylinder; these EFIs also require signals or power
feeds, typically from a microprocessor-controlled sub-system.
The electrical distribution system required to facilitate these various
signals and/or power feeds conventionally requires a considerable network
of wires, cables, harnesses, connectors, fasteners, brackets, standoffs,
strain reliefs, and one or more support frames for arranging, routing, and
supporting all of these elements, as illustrated in FIGS. 1-2. In
addition, most engines nowadays also require various other electrical
engine sub-systems, such as engine control modules, mass air flow sensor
modules, anti-lock brake control modules, and so forth. Each of these
sub-systems also requires its associated wires, harnesses, connectors,
housings, fasteners, etc., further adding to the electrical distribution
and routing system of the engine. Although these various sub-systems are
necessary, they may each add to the overall weight, space, complexity, and
cost of the engine.
It would be desirable, therefore, to provide some means of accommodating
the various signal and power feed needs of an engine system while reducing
the overall overall weight, space requirements, cost, and complexity
heretofore associated therewith.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the prior art
approaches by providing an apparatus for routing electrical signals in an
engine having n cylinders and an intake manifold, one embodiment of which
comprises: (1) a generally rigid housing generally conforming in shape
with and being removably attachable to a top surface of the intake
manifold; (2) at least n carrier members attached to the housing and
extending outward therefrom, wherein each carrier member is arranged in
general proximity with a respective cylinder; (3) a plurality of
conductive circuit traces arranged on or beneath a surface of the housing
and on or within each carrier member; and (4) at least one input/output
connector for connection to at least one of an external signal source, an
external power source, an external signal destination, and an external
power destination, wherein each input/output connector is attached to the
housing and is electrically connected to at least one of the circuit
traces. Each circuit trace carried by each carrier member terminates in a
termination electrically connectable with an electrical engine element,
such as an ignition coil, an EFI, a spark plug, and/or a glow plug.
It is an object and advantage that the present invention may accommodate
various signal and power needs of an engine electrical system while
reducing the weight, space requirements, cost, and complexity otherwise
associated therewith.
Another advantage is that the present invention may incorporate electronic
components from one or more electrical sub-systems of an engine so as to
provide even further overall reductions in weight, space requirements,
cost, and complexity.
These and other advantages, features and objects of the invention will
become apparent from the drawings, detailed description and claims which
follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a typical internal combustion
engine and associated intake manifold.
FIG. 2 is perspective view of another typical internal combustion engine
and associated intake manifold.
FIGS. 3-4 are top and perspective views, respectively, of a first
embodiment of the present invention.
FIG. 5 is a top view of an arm portion and terminations according to a
first embodiment of the present invention.
FIGS. 6A-C are top views of three possible configurations of a first
embodiment of the present invention.
FIGS. 7-9 are top views of a second embodiment of the present invention.
FIG. 10 is a sectional side view of a third embodiment of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIGS. 3-4 show a first embodiment 100 of the
present invention, namely a flex circuit for routing electrical signals in
an internal combustion engine 30 having n cylinders and an intake manifold
50. This embodiment comprises: (1) a flex circuit substrate 102 having a
body portion 104 and at least n arm portions 106 extending outward from
the body portion, wherein the body portion generally conforms in shape
with a top surface 52 of the intake manifold 50, and wherein each arm
portion is arranged in general proximity with a respective cylinder; (2) a
plurality of conductive circuit traces 108 arranged proximate (i.e., on or
beneath/within) at least one surface of the body portion 104 and of each
arm portion; and (3) at least one input/output connector 110 for
connection to at least one of an external signal source, an external power
source, an external signal destination, and an external power destination
(collectively designated by reference numeral 70), wherein each
input/output connector 110 is attached to the substrate 102 and is
electrically connected to at least one of the circuit traces 108. In this
embodiment, each circuit trace carried by each arm portion 106 terminates
in a termination 108t capable of electrical connection with at least one
electrical engine element 90, such as an ignition coil, an electronic fuel
injector, a spark plug, and/or a glow plug.
The substrate 102 is preferably a substantially flexible substrate, such as
a film, sheet, or lamination of polyetherimide, polyester, or other
materials used to make flex circuits. Alternatively, the substrate 102 may
comprise one or more metal foils or sheets with one or more layers of
insulative, conductive, and/or dielectric material selectively applied
thereto (e.g., by lamination, etching, or other additive or subtractive
processes). Although the substrate 102 is preferably generally flexible,
the body portion 104 may alternatively include at least one rigid
substrate portion 118 (e.g., an FR-4 daughter board) operably connected to
the remaining flexible body portion and/or arm portions. Likewise, the
entire body portion 104 may comprise a rigid substrate, to which flexible
substrate arm portions 106 are operably attached.
The substrate 102 may include a plurality of electronic components 114
operably attached to the circuit traces 108 thereon. These components 114
are preferably surface mount components, such as integrated circuit (IC)
chips, leadless chip components (LCCs) such as resistors and capacitors,
power devices, interconnect devices, and the like. It is possible to take
components from otherwise separate electronic control modules--including
but not limited to engine control modules, mass air flow sensor modules,
anti-lock brake control modules, speed control modules, throttle control
modules, fuse box modules, exhaust gas return (EGR) valve control modules,
engine temperature sensor control modules--and integrate the components
onto the flex substrate 102 of the present embodiment. This would provide
the advantage of eliminating the various housings, wires, cables,
harnesses, busses, interconnects, fasteners, etc. that are otherwise
needed for each individual module and incorporating only the necessary
parts therefrom (i.e., the electronic components) onto the flex substrate
102, thereby reducing cost, weight, space, and complexity for the overall
engine system.
The substrate 102 may further include a hole 116 in the body portion 104
thereof, through which a top portion of the intake manifold 50 or an end
portion of an air intake duct 56 may extend. The substrate 102 may also be
removably attachable to the top surface 52 of the intake manifold 50. This
may be done, for example, by providing holes in the substrate 102 through
which fasteners may be inserted for holding the substrate against the
manifold, or by providing fasteners integral with the substrate which
directly attach to the manifold.
Each arm portion 106 may include a rigid substrate member 120 on an end
thereof, wherein the termination of each circuit trace 108 on each arm
portion 106 is disposed on the rigid substrate member 120, as illustrated
in FIG. 5. Also, each circuit trace termination 108t on each arm portion
106 may comprise a male plug connector 122m, a female socket connector
122f, or a generally flat contact pad 122cp. These plug connectors
122m/122f may optionally be attached to or made integral with the rigid
substrate member 120 on the end of each arm portion 106.
The conductive circuit traces 108 may be similar to those found on
conventional rigid PCBs and flex circuits, such as the metallizations or
paths of copper or conductive ink applied to one or both planar sides of
such substrates. The traces 108 may also comprise wires or other
electrical conductors applied to a surface of the substrate 102, or which
are embedded, molded, or otherwise placed beneath a surface of the
substrate (i.e., within the substrate).
The input/output (I/O) connector 110 is used to connect one or more
substrate circuit trace(s) 108 (typically multiple traces) to one or more
external electrical elements 70. From the perspective of current flow
within the engine's electrical system, these external elements 70 may each
be an "upstream" source or a "downstream" destination (or both) with
respect to the I/O connector 110. The electrical flow to or from each of
these external elements to which the I/O connector is connected may be
generally designated as "signal" strength (e.g., milliamps, millivolts) or
"power" strength (e.g., 1+amps, 1+volts). Thus, an external "power source"
might be a 12-volt battery, a "power destination" might be a solenoid
requiring several amps/volts to actuate, a "signal source" might be a
150-millivolt output from a microprocessor, and a "signal destination"
might be a 150-millivolt input to the same microprocessor. Furthermore, it
should be understood that the electrical flow into and out of the I/O
connector 110 may at any time be continuous, intermittent/pulsed, or both.
The I/O connector 110 itself may assume any of the multitude of different
I/O connector configurations known in the art which can be operably
connected to a flexible, semi-rigid/rigiflex, or rigid substrate 102.
The present embodiment may also include a cover 112 capable of covering
substantially all of the body portion 104 and at least part of each arm
portion 106, as shown in FIG. 4. This cover 112 may be made out of
plastic, metal, fiberglass, and the like (or combinations thereof), may be
removably attachable to the intake manifold 50, and serves as a protective
covering for the underlying substrate, traces, etc. The cover 112 may
include a generally sealable hole therein through which the top portion of
the manifold or an end portion of the air intake duct may extend.
In its most basic form, the present embodiment 100 may be used to replace
the wires, cables, harnesses, support frame(s), and other related elements
used in conventional engine systems for routing and distributing
electrical signals to the engine's ignition coils, EFIs, spark plugs, glow
plugs, and/or other electrical engine elements 90, thus reducing cost,
space, weight, and complexity for the overall engine system. By further
including the electronic components from one or more engine control
modules as described above, further reductions can be realized. Moreover,
the savings and reductions made possible by the present invention relate
not only to the initial manufacturing and assembly of the engine system,
but also to the maintenance and service life of the engine system as well.
As an example of how the present embodiment might be used, the flex
circuit 100 might contain electronic components and interconnections such
that the flex circuit 100 may (1) take in signal and power from various
external sources (e.g., a battery output, a microprocessor output, a
switch output) via the I/O connector 110, (2) process and/or re-route the
signal/power within the flex circuit itself, and then (3) send out
signal/power feeds through both the I/O connector 110 and the arm portion
circuit traces to various external signal/power destinations (e.g.,
microprocessor inputs, solenoid inputs, electric motor contacts, spark
plugs, ignition coils, glow plugs, EFIs, etc.).
Many possible configurations exist for the present embodiment, as
illustrated in FIGS.6A-C for an engine having four cylinders (i.e., n=4).
In a first example, as shown in FIG. 6A, the substrate 102 may have
exactly n arm portions 106 (i.e., one for each cylinder) wherein the
circuit traces (not shown) on or within each arm portion 106 have
terminations capable of electrical connection with an ignition coil, an
EFI, a spark plug, and/or a glow plug associated with the respective
cylinder of each arm portion 106. Here, each arm portion 106 may generally
conform in shape with a top runner surface 54 associated with the
respective cylinder; the arm portions may then be laid atop (and
optionally attached to) their respective runners and covered with a cover
112 corresponding in overall shape with the body and arm portions 104/106
as laid out atop the manifold 52 and runners 54. In a second example, as
shown in FIG. 6B, the substrate 102 may have exactly n arm portions 106
with each dividing further into first and second branches 106'/106". In
this case, circuit traces (not shown) on or within each first branch 106'
have terminations (e.g., male plug connectors or female socket connectors)
capable of electrical connection with an ignition coil, while circuit
traces on or within each second branch 106" have terminations capable of
electrical connection with an EFI. In a third example, as shown in FIG.
6C, the substrate 102 has 2n arm portions 106, wherein circuit traces
proximate each arm portion 106 have terminations electrically connectable
with one of an ignition coil, an EFI, a spark plug, and a glow plug. Many
other configurations are also possible within the scope of the present
invention. In any case, generally, the flex circuit substrate 102 may be
draped and optionally attached onto the top surface 52 of the manifold 50,
and a cover 112 as described above may then be placed over the flex
circuit 102 and attached to the manifold 50.
A second embodiment of the present invention relates to an intake manifold
cover 200 for routing electrical signals in an internal combustion engine
30 having n cylinders and an intake manifold 50, as shown in FIGS. 7-9.
This embodiment comprises: (1) a generally rigid housing 230 generally
conforming in shape with and being removably attachable to a top surface
52 of the intake manifold 50; (2) at least n carrier members 240 attached
to the housing 230 and extending outward therefrom, wherein each carrier
member is arranged in general proximity with a respective cylinder; (3) a
plurality of conductive circuit traces 208 arranged on or beneath a
surface 232 of the housing 230 and on or within each carrier member 240;
and (4) at least one input/output connector 210 for connection to at least
one of an external signal source, an external power source, an external
signal destination, and an external power destination (designated
collectively by reference numeral 70), wherein each input/output connector
210 is attached to the housing 230 and is electrically connected to at
least one of the circuit traces 208. In this embodiment 200, each circuit
trace 208 carried by each carrier member 240 terminates in a termination
208t capable of electrical connection with at least one electrical engine
element 90, such as an ignition coil, an EFI, a spark plug, and/or a glow
plug.
This embodiment 200 combines many of the features of the flex substrate 102
and cover 112 of the first embodiment 100, but is not a mere combination
of these two elements. For example, whereas the first embodiment 100
includes a flex circuit substrate 102, the present embodiment 200 does not
necessarily include a flex substrate. Instead, the traces 208 (and
optional electronic components 214 operably connected thereto) of the
present embodiment 200 may be directly connected to a surface 232
(preferably an underside surface) of the housing 230, thereby eliminating
the need for a flex substrate. Of course, a flex substrate (and/or even a
rigid substrate or substrate portion) may be included if desired; for
example, the traces 208 and optional electronic components 214 may be
attached to a flex circuit substrate, with this substrate then being
attached to the underside or other surface 232 of the housing 230, or a
flex circuit substrate may first be attached to the underside or other
surface 232 and then the traces/components 208/214 attached thereto.
The generally rigid housing 230 may be (and preferably is) somewhat
flexible. It is described as being "generally" rigid in that it should be
able to generally maintain its shape when being handled (e.g., during
manufacture and installation), but should have some inherent flexibility,
as is the case with most thermoformed plastic parts, for example.
Like the first embodiment, the present embodiment 200 may assume many
different but related configurations. For example, as shown in FIG. 7,
each carrier member 240 may be an electrically insulative flexible
substrate which carries the one or more circuit traces 208 thereon or
therein. The flex substrate material in this case may be a flexible
elastomer, such as silicone, or may be made of polyester, polyetherimide,
or other suitable materials. These carrier members 240 may be attached to
a lateral edge and/or to an underside or other surface of the housing 230
by adhesives, mechanical fasteners, in-molding, etc., and serve to carry
signal/power between at least the I/O connector 210 and an electrical
engine element 90 such as an ignition coil, EFI, spark plug, and/or glow
plug. For example, each carrier member 240 may serve to carry
signals/power from the I/O 210 and/or optional electronics 214 to an
ignition coil and/or an EFI associated with the carrier member's
respective cylinder.
The housing 230 may comprise a body portion 230b and at least n arm
portions 230a extending outward from the body portion, wherein the body
portion generally conforms in shape with the top surface 52 of the
manifold 50, and wherein each arm portion 230a is arranged in general
proximity with a respective cylinder, as shown on the left-hand side of
the cover shown in FIG. 8. Alternatively, the housing 230 may comprise a
body portion 230b as just described and at least one shroud portion 230s
extending outward from the body portion on one or both lateral edges of
the body portion, as shown on the right-hand side of the cover shown in
FIG. 8. In either of these two housing configurations, the arm
portions/shroud portions 230a/230s are preferably made integral with the
body portion 230s, thus constituting a single piece which can be easily
molded. In these two configurations each carrier member 240 is preferably
attached to a corresponding arm portion 230a or shroud portion 230s, but
may alternatively be attached to the body portion 230b.
Each carrier member 240 and/or (if provided) each arm portion 230a made be
constructed so as to generally conform respective cylinder thereof.
Alternatively, rather than providing separate but geometrically similar
arm portions 230a and carrier members 240, the features of both may be
combined to comprise a configuration wherein each carrier member 240 is an
outwardly extending integral arm portion of the housing 230. That is,
rather than having carrier members which carry circuit traces thereon or
therein attached to separate, corresponding arm portions 230a or shroud
portions 230s, instead the circuit traces could be carried on or within an
underside (or other) surface of each arm or shroud portion 230a/230s--each
arm/shroud portion would both extend outward from the body portion 230b
and serve as a carrier for the circuit traces 208 associated with the arm
portion and respective cylinder, as illustrated in FIG. 9.
A third embodiment of the present invention is illustrated in FIG. 10, and
comprises: (1) a generally rigid housing 330 generally conforming in shape
with and being removably attachable to a top surface 52 of the intake
manifold, the housing 330 extending generally over each cylinder; (2) a
plurality of conductive circuit traces 308 arranged on or within an
underside or other surface of the housing and extending in general
proximity with each cylinder; (3) at least one input/output connector for
connection to at least one of an external signal source, an external power
source, an external signal destination, and an external power destination,
wherein each input/output connector is attached to the housing 330 and is
electrically connected to at least one of the circuit traces 308; and (4)
at least n electrical connectors 350 in-molded in the housing 330, wherein
each connector 350 is connected with at least one of the circuit traces
308 and is disposed within the housing 330 so as to be directly
connectable with an electrical engine element 90 when the housing 330 is
attached to the intake manifold 50. The housing portion(s) which extend
over each cylinder may comprise integral arm or shroud portions, similar
to FIG. 9.
As shown in FIG. 10, the intake manifold cover 300 may further comprise at
least one fuel rail 360 integral with the housing 330, wherein each fuel
rail is directly and sealably connectable with at least one electronic
fuel injector 94 so as to provide sealable fluid communication between the
fuel rail and each EFI connectable thereto. Preferably, the cover 330 is
made of molded plastic and includes either one fuel rail 360 for
slant-type or in-line engines or two fuel rails 360 for V-type engines.
The fuel rail(s) 360 may be conventional metal fuel rails that are insert
molded into the housing 330, or (as shown in FIG. 10) may be metallized or
non-metallized channels formed within the housing 330 by lost-core or
other molding processes.
The cover 300 of the present embodiment may include n electrical connectors
350 disposed within the housing 330. Each connector 350 is directly
connectable with a mating electrical connector portion 94c of a respective
electronic fuel injector 94 when the housing 330 is placed atop and
attached to the intake manifold 50.
At least a subset of the circuit traces 308 may be in-molded within the
housing 330 and may comprise a metal stamping, a flex circuit, or a
network of wires within the housing. Preferably this subset of traces are
each operably connected with the at least n electrical connectors 350.
One advantage of the present embodiment is that the cover 300 may be fitted
over and attached to the manifold 50 with the aforementioned electrical
connectors 350 fitting directly atop their respective electrical engine
elements 90. For example, a cover may have connectors 350 in-molded
therein which may simultaneously mate directly with the mating electrical
connector portions of n ignition coils and n fuel injectors when the cover
is lowered onto and attached to the manifold 50, without requiring
additional steps or interconnecting components (e.g., wire harnesses or
cables) for connecting the coils and EFIs with their power/signal sources.
Adding the fuel rails 360 as described above further reduces complexity
and installation effort.
Various other modifications to the present invention will, no doubt, occur
to those skilled in the art to which the present invention pertains. For
example, although only V-type engines are shown in the drawings, the
present invention also relates to slant-type engines, in-line engines,
rotary engines, etc. It should also be understood that the present
invention relates to both gasoline and diesel internal combustion engines,
as well as to hybrid electric/internal combustion engines. The present
invention applies to engines using spark plugs, glow plugs, or
compression-ignition-only; to those having carburetors, EFIs, or other
related systems; and to those having central distributors, coil-on-plug,
and other related spark activation systems. Furthermore, while the arm
portions, shroud portions, and carrier members have been described above
as being connected to or integral with a cover, housing, or body portion,
it is within the scope of the present invention that the arm portions,
shroud portions, and carrier members may be removably connectable with
their associated cover, housing, or body portion, such as by using mating
male/female electrical connectors. Also, the housing or cover may include
louvers, vanes, and the like for directing some amount of air from the air
intake duct across the circuit traces and optional electronic components,
so as to assist in cooling these elements during operation. Also, although
in the drawings the intake manifold is shown (for simplicity) sitting
essentially within the confines of the top surface of the engine, the
manifold may include portions extending beyond the top surface of the
engine, such as an air intake tube, a throttle body housing, etc.
Moreover, it should be understood that while the arm portions and carrier
members have variously been described as being connected to ignition
coils, EFIs, spark plugs, and glow plugs, it is contemplated that other
electrical engine elements may be used instead of or in addition to these
four highlighted elements, such as engine sensors, climate sensors,
solenoids, switches, etc., whether sending or receiving signals to or from
the present invention. Additionally, it should be understood that the use
of the word "signal" as variously used herein may encompass both
relatively low voltage/low amperage triggering signals and relatively high
voltage/high amperage power feeds, whether sent/received in intermittent
pulses or in continuous non-pulsed form. Finally, the present invention
further includes a flex circuit similar to the first embodiment, but which
has no arm portions, or less than n arm portions, and which may not
necessarily include any element which is generally proximate to or related
with any engine cylinder. It is the following claims, including all
equivalents, which define the scope of the present invention.
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